Deploying wellbore patch for mitigating lost circulation

Abstract

Systems, methods, and apparatuses for deploying a lost circulation fabric (LCF) to seal a lost circulation zone during a drilling operation. The LCF may be contained within a lost circulation fabric deployment system (LCFDS) that is coupled to a tubular of a drilling string. The LCFDS may include a controller and sensors to detect the presence of a lost circulation zone and deploy the LCF upon detection of the lost circulation zone. In some implementations, a plurality of LCFDSs may be disposed on the tubular and work in cooperation to deploy a plurality of LCFs to form a seal along the lost circulation zone.

What is claimed is: 
     
       1. A lost circulation fabric (LCF) deployment system (LCFDS) for deploying an LCF at a lost circulation zone within a wellbore, the LCFDS comprising:
 a housing configured to be coupled to a tubular, the housing defining a cavity; 
 an opening formed in the housing, the opening providing communication between the cavity and an exterior of the housing; 
 a door moveable between a closed position to cover the opening formed in the housing and an opened position to uncover the opening formed in the housing; 
 an LCF disposed in the cavity; 
 a float coupled to the LCF, the float comprising a material having a mass density less than a mass density of drilling mud such that the float is buoyant when in the drilling mud; and 
 a release system coupled to the LCF, the release system operable to move the door between the closed position and open position to permit deployment of the LCF. 
 
     
     
       2. The LCFDS of  claim 1 , wherein the float is operable to deploy the LCF from the opening formed in the housing. 
     
     
       3. The LCFDS of  claim 1 , wherein the housing is sized and shaped to reside within an annular space within a wellbore between the tubular and a wall of the wellbore. 
     
     
       4. The LCFDS of  claim 1 , wherein the LCF comprises a flexible mesh material. 
     
     
       5. The LCFDS of  claim 4 , wherein the flexible mesh material is a fiber-reinforced polymer. 
     
     
       6. The LCFDS of  claim 1 , further comprising a controller and a sensor, the controller operable to receive data from the sensor to detect a presence of a lost circulation zone and to actuate the release system to deploy the LCF in response to detection of a lost circulation zone. 
     
     
       7. The LCFDS of  claim 1 , further comprising a launch system operable to forcefully eject the LCF from the opening formed in the housing during deployment of the LCF. 
     
     
       8. The LCFDS of  claim 7 , wherein the launch system comprises a compressible spring that is operable to expand to forcefully eject the LCF. 
     
     
       9. The LCFDS of  claim 7 , wherein the launch system comprises a platform moveable within the cavity of the housing, the platform operable to eject the LCF from the opening formed in the housing during deployment of the LCF. 
     
     
       10. The LCFDS of  claim 1 , wherein the LCF comprises a first end and a second end, and further comprising a compressible spring disposed between the first end and the second end, the compressible spring configured to expand upon deployment of the LCF to separate the first end and the second end. 
     
     
       11. The LCFDS of  claim 1 , wherein the LCF comprises an edge, and wherein the float is coupled to the LCF along the edge. 
     
     
       12. The LCFDS of  claim 1 , wherein the float is coupled to an end of the LCF by a cable, a string, a line, or a cord. 
     
     
       13. The LCFDS of  claim 1 , wherein the material of the float comprises a metal foam. 
     
     
       14. The LCFDS of  claim 1 , wherein the float is a first float and the LCFDS further comprises a second float coupled to the LCF. 
     
     
       15. The LCFDS of  claim 14 , wherein the first and second floats are located at opposing ends of the LCF. 
     
     
       16. The LCFDS of  claim 1 , wherein the release system is operable to release the float into the drilling mud to cause the float to rise within the drilling mud to extract the LCF from the housing. 
     
     
       17. A system for deploying a lost circulation fabric (LCF), the system comprising:
 a lost circulation fabric deployment system (LCFDS) configured to be coupled to a tubular, the LCFDS comprising:
 a housing defining a cavity; 
 an opening formed in the housing, the opening providing communication between the cavity and an exterior of the housing; 
 a door moveable between a closed position to cover the opening formed in the housing and an opened position to uncover the opening formed in the housing; 
 an LCF disposed in the cavity; 
 a float coupled to the LCF, the float comprising a material having a mass density less than a mass density of drilling mud such that the float is buoyant when in the drilling mud, the float operable to deploy the LCF; and 
 a release system coupled to the LCF, the release system operable to move the door between the closed position and open to permit deployment of the LCF. 
 
 
     
     
       18. The system of  claim 17 , wherein the LCFDS further comprises a controller and a sensor and wherein the controller is operable to receive data from the sensor to detect a presence of a lost circulation zone and to actuate the release system to deploy the LCF in response to detection of a lost circulation zone. 
     
     
       19. The system of  claim 17 , further comprising a plurality of LCFDSs disposed in an annular arrangement and wherein the LCFs of adjacent LCFDSs are coupled together. 
     
     
       20. The system of  claim 19 , wherein the coupled LCFs form a unitary annular ring upon deployment of the LCFs. 
     
     
       21. The system of  claim 19 , wherein the plurality of LCFDSs are configured to deploy coupled LCFs simultaneously. 
     
     
       22. The system of  claim 17 , wherein the LCFDS further comprises a launch system operable to forcefully eject the LCF from the opening formed in the housing during deployment of the LCF. 
     
     
       23. The system of  claim 22 , wherein the launch system comprises a platform moveable within the cavity of the housing, the platform operable to eject the LCF from the opening formed in the housing during deployment of the LCF. 
     
     
       24. The system of  claim 23 , wherein the launch system comprises a compressible spring that is operable to expand to forcefully eject the LCF. 
     
     
       25. The system of  claim 23 , wherein the launch system comprises a platform moveable within the cavity of the housing, the platform operable to eject the LCF from the opening formed in the housing during deployment of the LCF.